Building Panel Assembly

ABSTRACT

A building panel assembly is provided. The building panel assembly comprises a plurality of pyramidal elements with each pyramidal element having an apex with a plurality of pyramidal feces extending to a base, each face separated from each adjacent face by a face edge, and the base having base edges. A plurality of inverse pyramidal elements are provided with each inverse pyramidal element having inverse pyramidal faces and mateable with the pyramidal elements. A flattened edge is formed along the face edges between each of the pyramidal faces creating a continuous adhesive flow channel and an adhesive substance positionable within the continuous adhesive flow channel. Upon mating, the pyramidal elements with the inverse pyramidal elements, the adhesive travels through the continuous adhesive flow channel and upon hardening the adhesive substance creates a space truss structure thereby strengthening the building panel assembly.

The present application claims benefit of priority of pendingprovisional patent application Ser. No. 61/583,579, filed on Jan. 5,2012, entitled “Reinforced Structural Insulated Panel”, and pendingprovisional patent application Ser. No. 61/533,139, filed on Sep. 9,2011, entitled “Structural Insulated Panel”.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to a building panel assembly and, moreparticularly, the invention relates to a building panel assembly formingstructural insulated panel created from uniformly sized and shapedpyramidal elements having adhesive flow channels forming a space trussstructure.

2. Description of the Prior Art

Structural insulated panels (SIPs) are revolutionizing the structures ofbuildings. The earliest concept of structural sandwich-panel technologywas developed in the 1930s at the Forest Products Laboratory (FPL) inMadison, Wis. FPL engineers proposed that plywood and hardboardsheathing could take a portion of the structural load in wallapplications. Their prototype was used to construct test homes thatcontinued to be monitored over thirty years, then disassembled andreexamined. During this time, FPL engineers continued to experiment withnew designs and materials.

Famed architect Frank Lloyd Wright used SIPs In his affordable Usonianhouses built throughout the 1930s and 1940s. Wright attempted toincorporate beauty and simplicity into relatively low-cost homes. Someof the walls in these houses consisted of three layers of plywood andtwo layers of tar paper but lacked insulation.

SIPs advanced in technology when one of Wright's students, Alden B. Dow,brother of the founder of Dow Chemical Company, created the first foamcore SIP in 1952. Dow, concerned about energy efficiency, was dismayedby the lack of insulation in the Usonian homes. He experimented with theengineering of structural panels with insulation and is now generallycredited with producing the first structural insulated panels. His SIPhouses were built in Michigan using panels composed of 1⅝ inch Styrofoamcores and 3/16 inch plywood facings for the load-bearing walls andinstalled over roof framing on 42 inch centers.

By 1959, the Koppers Company converted an auto production plant inDetroit into a SIP production facility and in the 1960s began the firstmanufacturing effort of structural insulated panels, resulting in theproduction of SIPs as we know them today.

Today, SIPs offer a high tech solution for residential and low risenonresidential buildings. Advances in computer aided design andmanufacturing allow SIPs to be produced with amazing accuracy to deliverflat, straight, and true walls. SIPs are now made with a variety ofstructural skin materials, including oriented strand board (OSB),treated plywood, fiber-cement board, and metal. SIPs are available inthickness from 4-inch and 6-inch walls, and thicker roof panels up to14-inches, depending on climate conditions. The design capabilities,exceptional strength and energy saving insulation make SIPs atwenty-first century building material for high performance buildings.

SUMMARY

The present invention is a building panel assembly. The building panelassembly comprises a plurality of pyramidal elements with each pyramidalelement having an apex with a plurality of pyramidal faces extending toa base, each face separated from each adjacent face by a face edge, andthe base having base edges. A plurality of inverse pyramidal elementsare provided with each inverse pyramidal element having inversepyramidal faces and mateable with the pyramidal elements. A flattenededge is formed along the face edges between each of the pyramidal facescreating a continuous adhesive flow channel and an adhesive substancepositionable within the continuous adhesive flow channel. Upon matingthe pyramidal elements with the inverse pyramidal elements, the adhesivetravels through the continuous adhesive flow channel and upon hardeningthe adhesive substance creates a space truss structure therebystrengthening the building panel assembly.

In addition, the present invention includes a building panel assemblyhaving a plurality of pyramidal elements with each pyramidal elementhaving an apex with a plurality of pyramidal faces extending to a base,each face separated from each adjacent face by a face edge, and the basehaving base edges. A plurality of inverse pyramidal elements is providedwith each inverse pyramidal element having inverse pyramidal faces andthe pyramidal elements mateable with the inverse pyramidal elements. Aflattened edge is formed along the face edges between each of thepyramidal faces creating a continuous adhesive flow channel. Horizontaladhesive flow channels are formed along the pyramidal faces with each ofthe horizontal adhesive flow channels fluidly connected to thecontinuous adhesive flow channel. Angled adhesive flow channels areformed along the pyramidal faces with each of the angled adhesive flowchannels fluidly connected to the continuous adhesive flow channel andthe horizontal adhesive flow channels. An adhesive substance ispositionable within the flow channels wherein upon hardening, theadhesive substance creates a space truss structure thereby strengtheningthe building panel assembly.

The present invention further includes a method for constructing abuilding panel assembly. The method comprises providing a plurality ofpyramidal elements with each pyramidal element having an apex with aplurality of pyramidal faces extending to a base, each face separatedfrom each adjacent face by a face edge, and the base having base edges,providing a plurality of inverse pyramidal elements with each inversepyramidal element having inverse pyramidal faces, inserting thepyramidal elements into the inverse pyramidal elements, flattening theface edges between each of the pyramidal faces creating a continuousadhesive flow channel, forming horizontal adhesive flow channels alongthe pyramidal faces, fluidly connecting each of the horizontal adhesiveflow channels to the continuous adhesive flow channel, forming angledadhesive flow channels along the pyramidal faces, fluidly connectingeach of the angled adhesive flow channels to the continuous adhesiveflow channel and the horizontal adhesive flow channels, positioning anadhesive substance within the flow channels, and creating a space trussstructure with the hardened adhesive substance.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view illustrating a single unit moduleof a building panel assembly, constructed in accordance with the presentinvention, having a right cuboid element and with a pyramidal elementextending therefrom receivable within an inverse pyramidal element withadhesive flow channels formed in corner edges of the right cuboid andthe edges of the pyramidal element;

FIG. 2 is an exploded perspective view illustrating the building panelassembly, constructed in accordance with the present invention, composedof a plurality of single unit modules;

FIG. 3 is a top view illustrating the adhesive flow channels of thebuilding panel assembly of FIG. 2, constructed in accordance with thepresent invention, with the adhesive flow channels creating a spacetruss structure;

FIG. 4 is an elevational side view illustrating the adhesive flowchannels of the building panel assembly of FIG. 2, constructed inaccordance with the present invention, with the adhesive flow channelscreating a space truss structure;

FIG. 5 is a perspective view illustrating the adhesive flow channels ofthe building panel assembly of FIG. 2, constructed in accordance withthe present invention, with the adhesive flow channels creating a spacetruss structure;

FIG. 6A is a perspective view illustrating another embodiment of thebuilding panel assembly, constructed in accordance with the presentinvention;

FIG. 6B is an elevational side view illustrating the building panelassembly of FIG. 6A, constructed in accordance with the presentinvention;

FIG. 7 is an exploded perspective view illustrating another embodimentof the building panel assembly, constructed in accordance with thepresent invention;

FIG. 8 is a perspective view illustrating the building panel assembly ofFIG. 7, constructed in accordance with the present invention;

FIG. 9 is an exploded perspective view illustrating still anotherembodiment of the building panel assembly, constructed in accordancewith the present invention;

FIG. 10 is a semi-exploded perspective view illustrating the buildingpanel assembly of FIG. 9, constructed in accordance with the presentinvention;

FIG. 11 is perspective schematic view illustrating the building panelassembly of FIG. 9, constructed in accordance with the presentinvention;

FIG. 12 is a perspective view illustrating yet another embodiment of thebuilding panel assembly, constructed in accordance with the presentinvention;

FIG. 13 is a schematic perspective view of the building panel assemblyof FIG. 12, constructed in accordance with the present invention, withthe adhesive flow channels represented;

FIG. 14 is a schematic top view of the building panel assembly of FIG.12, constructed in accordance with the present invention, with theadhesive flow channels represented;

FIG. 15 is a schematic side view of the building panel assembly of FIG.12, constructed in accordance with the present invention, with theadhesive flow channels represented; and

FIG. 16 is a schematic end view of the building panel assembly of FIG.12, constructed in accordance with the present invention, with theadhesive flow channels represented.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As illustrated in FIG. 1-14, the present invention is a building panelassembly, indicated generally at 10, forming a structural insulatedpanel created from uniformly sized and shaped pyramidal elements havinga continuous adhesive flow channel 22 thereby forming a space trussstructure. By definition, a space frame truss is a structurally sound,three-dimensional framework of members pinned at their ends. Thebuilding panel assembly 10 provides an independent adhesive flow channel22 creating internal reinforcement of the entire structural insulatedpanel.

The building panel assembly 10 of the present invention includes a firstrigid diaphragm panel 12 having a first side surface and a second sidesurface and a second rigid diaphragm panel 14 having a first sidesurface and a second side surface. A right cuboid element 16 is mountedto the first side surface of the first rigid diaphragm panel 12 witheach right cuboid 16 element having a pyramidal element 18 extendingtherefrom. An inverse pyramidal element 20 is mounted to the first sidesurface of the second rigid diaphragm 14. Preferably, the right cuboidelement 16 and the inverse pyramidal element 20 are mounted to the firstrigid diaphragm panel 12 and the second rigid diaphragm panel 14 by anadhesive material or the like.

It should be noted that while the building panel assembly 10 has beendescribed as having a right cuboid element 16 mounted directly to thefirst side surface of the first rigid diaphragm panel 12, it is withinthe scope of the present invention to completely remove the right cuboidelement 16 from the construction of the building panel assembly 10. Inthis instance, the base of the pyramidal element 18 will be mounteddirectly to the first rigid diaphragm panel 12 or to another pyramidalelement, as described in further detail below.

Preferably, the building panel assembly 10 of the present invention hasa plurality of uniformly sized and shaped pyramidal elements 18 and aplurality of uniformly sized and shaped inverse pyramidal elements 20.The pyramidal elements 18 and the inverse pyramidal elements 20 arepreferably both constructed of an insulating material with the pyramidalelements 18 mateable with the inverse pyramidal elements 20 to form thestructural insulated panel of the building panel assembly 10 with thefirst rigid diaphragm panel 12 and the second rigid diaphragm panel 14sandwiching the mated pyramidal elements 18 and the inverse pyramidalelements 20. The mating of the pyramidal elements 18 and the inversepyramidal elements 20 inhibits lateral movement of the pyramidal element18 relative to the inverse pyramidal element 20.

In a preferred embodiment, the right cuboid element 16 of the buildingpanel assembly 10 of the present invention has twelve edges. Eachpyramidal element 18 has an apex with four side edges extending to asquare base with a first horizontal edge between the right cuboidelement 16 and the pyramidal element 18 and four vertical base edgesextending from the first horizontal edge to a second horizontal edge atthe base of the right cuboid element 16. In an embodiment of the presentinvention, all of the edges of the pyramidal elements 18 are removed. Inanother embodiment of the present invention, the first horizontal edgeand/or the second horizontal edge are removed. In still anotherembodiment of the present invention, in addition to the removal of theedges of the pyramidal elements 18, all of the vertical edges of theright cuboid element 16 are also removed. The removed edges create acontinuous adhesive flow channel when the pyramidal elements 18 and theinverse pyramidal elements 20 are mated together. Additional angled,horizontal and/or vertical adhesive flow channels 22 can be formed inthe pyramidal elements for additional structural enhancements of thestructural insulated panel.

The building panel assembly 10 of the present invention further includesan adhesive applied to the pyramidal elements 18 and the inversepyramidal elements 20. The adhesive collects in and flows through theadhesive flow channels 22 created by the removed edges. Basically, uponhardening of the adhesive substance, the adhesive flow channels 22create internal reinforcement of the structural insulated panel byeffectively forming the struts of a space truss structure within thebuilding panel assembly 10. With the struts of the space truss structurein place, the structural insulated panel of the building panel assembly10 has greater strength with lower cost than conventional structuralinsulated panels

Further embodiments of the building panel assembly 10 of the presentinvention can be formed using the principals of pyramidal elements 18and inverse pyramidal elements 20, as described above. For instance, asbest illustrated in FIGS. 7 and 8, an additional pyramidal element 18 isadded in addition to additional side elements 24 to finish the edges ofthe building panel assembly 10. The side elements 24 have pyramidalelements 18 with adhesive flow channels 22 allowing the adhesive tofurther construct and strengthen the space truss structure. As bestillustrated in FIGS. 9-11, the building panel assembly 10 includes anadditional pyramidal element mounted in an opposite fashion to the otherpyramidal elements 18 with additional inverse pyramidal elements 20. Aswith the teachings above, the edges of the pyramidal elements 18 areremoved creating the adhesive flow channels 22. As best illustrated inFIGS. 12-16, similar to FIGS. 7 and 8, the building panel assembly 10has side elements. The adhesive flow channels 22 creating the spacetruss structure are visible when the other elements are removed.

The foregoing exemplary descriptions and the illustrative preferredembodiments of the present invention have been explained in the drawingsand described in detail, with varying modifications and alternativeembodiments being taught. While the invention has been so shown,described and illustrated, it should be understood by those skilled inthe art that equivalent changes in form and detail may be made thereinwithout departing from the true spirit and scope of the invention, andthat the scope of the present invention is to be limited only to theclaims except as precluded by the prior art. Moreover, the invention asdisclosed herein may be suitably practiced in the absence of thespecific elements which are disclosed herein.

What is claimed is:
 1. A building panel assembly comprising; a pluralityof pyramidal elements, each pyramidal element having an apex with aplurality of pyramidal faces extending to a base, each face separatedfrom each adjacent face by a face edge, the base having base edges; aplurality of inverse pyramidal elements, each inverse pyramidal elementhaving inverse pyramidal faces, the pyramidal elements mateable with theinverse pyramidal elements: a flattened edge formed along the face edgesbetween each of the pyramidal faces creating a continuous adhesive flowchannel; and an adhesive substance positionable within the continuousadhesive flow channel; wherein upon mating the pyramidal elements withthe inverse pyramidal elements with the pyramidal faces contacting theinverse pyramidal faces, the adhesive travels through the continuousadhesive flow channel; and wherein upon hardening, the adhesivesubstance creates a space truss structure thereby strengthening thebuilding panel assembly.
 2. The building panel assembly of claim 1 andfurther comprising: a first rigid diaphragm panel having a first sidesurface and a second side surface, the base of the pyramidal elementsmounted to the first side surface of the first rigid diaphragm panel;and a second rigid diaphragm panel having a first side surface and asecond side surface, the inverse pyramidal elements mounted to thesecond side surface of the second right diaphragm panel.
 3. The buildingpanel assembly of claim 1 and further comprising: a cuboid secured tothe base of each first pyramidal element, each cuboid having flattenededges; wherein the flattened edges of the cuboid create an additionaladhesive flow channel; and wherein the additional adhesive flow channelis fluidly connected and continuous with the continuous adhesive flowchannel thereby creating additional struts for the space trussstructure.
 4. The building panel assembly of claim 3 wherein eachpyramidal element has an apex with four first pyramidal faces extendingto a square base with four base edges and each cuboid is a right cuboid.5. The building panel assembly of claim 3 and further comprising: afirst rigid diaphragm panel having a first side surface and a secondside surface, the first right cuboid element mounted to the first sidesurface of the first rigid diaphragm panel.
 6. The building panelassembly of claim 1 and further comprising: horizontal adhesive flowchannels formed along the pyramidal faces, each of the horizontaladhesive flow channels fluidly connected to the continuous adhesive flowchannel.
 7. The building panel assembly of claim 1 and furthercomprising; angled adhesive flow channels formed along the pyramidalfaces, each of the angled adhesive flow channels fluidly connected tothe continuous adhesive flow channel.
 8. The building panel assembly ofclaim 1 and further comprising: vertical adhesive flow channels formedalong the pyramidal faces, each of the vertical adhesive flow channelsfluidly connected to the continuous adhesive flow channel.
 9. Thebuilding panel assembly of claim 1 and further comprising: a pluralityof side elements, each of the side elements having side element adhesiveflow channels in fluid communication with the continuous adhesive flowchannel.
 10. The building panel assembly of claim 1 and furthercomprising: a plurality of additional pyramidal elements, the additionalpyramidal elements being identical to the pyramidal elements; aplurality of additional inverse pyramidal elements, the additionalinverse pyramidal elements being identical to the inverse pyramidalelements, the pyramidal elements mateable with the inverse pyramidalelements; and additional adhesive flow channel created by flatteningedges of the additional pyramidal elements; wherein the base of thepyramidal elements is secured to the base of the additional pyramidalelements and the additional adhesive flow channel is fluidly connectedto the continuous adhesive flow channel.
 11. A building panel assemblycomprising: a plurality of pyramidal elements, each pyramidal elementhaving an apex with a plurality of pyramidal faces extending to a base,each face separated from each adjacent face by a face edge, the basehaving base edges; a plurality of inverse pyramidal elements, eachinverse pyramidal element having inverse pyramidal faces, the pyramidalelements mateable with the inverse pyramidal elements; a flattened edgeformed along the face edges between each of the pyramidal faces creatinga continuous adhesive flow channel; horizontal adhesive flow channelsformed along the pyramidal faces, each of the horizontal adhesive flowchannels fluidly connected to the continuous adhesive flow channel;angled adhesive flow channels formed along the pyramidal faces, each ofthe angled adhesive flow channels fluidly connected to the continuousadhesive flow channel and the horizontal adhesive flow channels; and anadhesive substance positionable within the flow channels; wherein uponapplying the adhesive substance within the adhesive flow channels, theadhesive substance, when hardened, creates a space truss structurethereby strengthening the building panel assembly.
 12. The buildingpanel assembly of claim 11 and further comprising: a first rigiddiaphragm panel having a first side surface and a second side surface,the base of the pyramidal elements mounted to the first side surface ofthe first rigid diaphragm panel; and a second rigid diaphragm panelhaving a first side surface and a second side surface, the inversepyramidal elements mounted to the second side surface of the secondright diaphragm panel.
 13. The building panel assembly of claim 11 andfurther comprising: a cuboid secured to the base of each first pyramidalelement, each cuboid having flattened edges; wherein the flattened edgesof the cuboid create an additional adhesive flow channel; and whereinthe additional adhesive flow channel is fluidly connected and continuouswith the continuous adhesive flow channel thereby creating additionalstruts for the space truss structure.
 14. The building panel assembly ofclaim 13 and further comprising: a first rigid diaphragm panel having afirst side surface and a second side surface, the first right cuboidelement mounted to the first side surface of the first rigid diaphragmpanel.
 15. The building panel assembly of claim 11 and furthercomprising: vertical adhesive flow channels formed along the pyramidalfaces, each of the vertical adhesive flow channels fluidly connected tothe continuous adhesive flow channel.
 16. A method for constructing abuilding panel assembly, the method comprising: providing a plurality ofpyramidal elements, each pyramidal element having an apex with aplurality of pyramidal faces extending to a base, each face separatedfrom each adjacent face by a face edge, the base having base edges;providing a plurality of inverse pyramidal elements, each inversepyramidal element having inverse pyramidal faces; inserting thepyramidal elements into the inverse pyramidal elements; flattening theface edges between each of the pyramidal faces creating a continuousadhesive flow channel; forming horizontal adhesive flow channels alongthe pyramidal faces; fluidly connecting each of the horizontal adhesiveflow channels to the continuous adhesive flow channel; forming angledadhesive flow channels along the pyramidal faces; fluidly connectingeach of the angled adhesive flow channels to the continuous adhesiveflow channel and the horizontal adhesive flow channels; positioning anadhesive substance within the flow channels; and creating a space trussstructure with the hardened adhesive substance.
 17. The method of claim16 and further comprising: providing a first rigid diaphragm panelhaving a first side surface and a second side surface; mounting the baseof the pyramidal elements to the first side surface of the first rigiddiaphragm panel; providing a second rigid diaphragm panel having a firstside surface and a second side surface; and mounting the inversepyramidal elements to the second side surface of the second rightdiaphragm panel.
 18. The method of claim 16 and further comprising:securing a cuboid to the base of each first pyramidal element, eachcuboid having flattened edges; creating additional adhesive flowchannels with the flattened edges; and fluidly connecting the additionaladhesive flow channels with the continuous adhesive flow channel therebycreating additional struts for the space truss structure.
 19. The methodof claim 18 and further comprising: providing a first rigid diaphragmpanel having a first side surface and a second side surface; andmounting the first right cuboid element to the first side surface of thefirst rigid diaphragm panel.
 20. The method of claim 16 and furthercomprising: forming vertical adhesive flow channels along the pyramidalfaces; and fluidly connecting each of the vertical adhesive flowchannels to the continuous adhesive flow channel.